AGRICULTURAL MACHINERY MANUFACTURERS

NDUME LIMITED P O Box 62, 20116 Gilgil, Kenya Tel 020‐2186668/9, 2186671/2 Email info@ndumekenya.com

www.ndumekenya.com

HYDRAULIC OPERATED INTERLOCKING BRICK MAKING MACHINE

CONTENTS

Hydraulic Interlocking Brick Machine Drawing ‐ Page 1 Hydraulic interlocking Brick Machine Parts ‐ Page 2 Maintenance ‐ Page 3 Set Up of Production Line ‐ Page 4 Soil Types ‐ Page 5 Preparation ‐ Page 5 Mixing ‐ Page 5 Set Up Procedure ‐ Page 6 Different Brick Cement Ratios ‐ Page 6 To Produce One Brick ‐ Page 7 to 10 Curing of Bricks ‐ Page 10 Finishing ‐ Page 10 Disclaimer ‐ Page 10

1.

NDUME INTER‐LOCKING BRICK MAKING HYDRAULIC MACHINE

PART NO DESCRIPTION

1 BASE PLATE

2 OIL TANK

3 BRICK COMPRESSION CHAMBER

4 BRICK COMPRESSION CHAMBER LID

5 HYDRAULIC PUMP

6 HYDRAULIC PUMP SUPPORT

7 DRIVE PULLEY

8 DRIVE VEE BELT B59

9 PISTON LOCK

10 LID LOCKING BRACKET

11 LID PIVOT PIN

12 BELT GUARD SECURING BOLT S/WASHER

13 BELT GUARD

14 SOIL HOPPER

15 DRIVE ENGINE 16 HP

16 HYDRAULIC RAM

17 LID WEIGHT

18 PIVOT PIN LOCKING BOLT & S/WASHER

19 HYDRAULIC RAM LOCK

20 SPOOL VALVE CONTROL

21 STARTER HANDLE BOX

22 HYDRAULIC MOTOR OIL INPUT PIPE

23 HYDRAULIC MOTOR OIL OUTPUT PIPE

24 SPOOL VALVE CONTROL OIL RETURN PIPE

25 HYDRAULIC RAM TOP PIPE

26 HYDRAULIC RAM LOWER PIPE

27 ACCELERATOR KNOB

28 STARTER HANDLE

2.

MAINTENANCE

• Before you start your machine, read through the diesel engine operation manual • Before starting the engine, check engine oil. • Water level should be checked at least once an hour when working. • Grease the two bearings on the hydraulic pump drive once a week. • Check for leaks on all pipes and connections. • Check the oil level in the hydraulic tank once a month. If it needs to be topped up, use Shell

hydraulic oil Tellus S2M‐46. Oil level should be 4½” from the top of the filler cap. • Check all nuts and bolts daily for the first week of work, and then once a month thereafter. • If using daily, change engine oil once a month. Recommended oil is Shell R2 SAE40 diesel oil. • For all other maintenance, follow the procedures in the operations manual.

TOOLS SUPPLIED

1. Spanner for adjustment bolts 2. Grease gun 3. Oil funnel 4. Toolbox as supplied with the 16HP engine, which includes assorted engine spare parts.

3.

SETUP OF PRODUCTION LINE Once you have established where you are going to make your bricks, it is a good idea to set up your production site in such a way as to have a free flowing production line in order to minimize labour, time and cost. It is a good idea to have your machine and mixing area all under some shade. You also want your water supply at your place of mixing and curing – either by tap or water tank. You must level out where you are going to put your machine/s so that the machine is sitting level

4.

Soil to be used

Sieving

Area

Cement and Tool Store

Mixing Area

Brick

Making Machine

Curing of Bricks

Water Supply

Shaded area

1. SOIL TYPE

When looking for the right soil type, you should use soil from the subsoil, so as to avoid any organic matter. The best soil type is sandy loam (more sand than clay). Your optimum ration is 70% sand to 30% clay silt content. The reason for this is too much sand causes difficulties in handling, and too much clay causes the brick to shrink and in doing so they crack. If your soil has too much clay you can add sand to get the right ration.

2. PREPARATION Once you had dug your soil for your brick making, it is a good idea to sieve it, as this will remove large lumps and stones. A sieve with holes between 5mm and 10mm should be used.

3. MIXING Your cement to soil ratio can be anywhere from 5% to 12% cement. Once you have determined what ratio you are going to use, you can then start your mass mixing. The easiest method for preparing your mixture is to have a container that holds the same amount as a bag of cement. The cement must come level with the top of the container so that measuring one part cement will be the same as one part soil. Here are some example of different mixing ratios:

5% Mix = 1 bag Cement : 20 parts Soil 8% Mix = 1 bag Cement : 12 Parts Soil 10% Mix = 1 bag Cement : 10 parts Soil 12% Mix = 1 bag Cement : 8 parts Soil

When mixing it is advisable to only mix one bag of cement at a time so you get an even mixture. Start by mixing your soil and cement until mixed thoroughly. Then add water – this must be done slowly and evenly, ideally using a watering can. You need to make sure you add the right amount of water to your mixture. Too dry mixture will make your brick crumble when handled and too wet will make your brick lose shape and crack. Ideally you want a mixture which when you squeeze it in your hand it sticks together and when you push your thumb into it, it will break into a few pieces. When you compress your brick there should be no visual sign of water on the top of the brick or on the lid and sides of the machine.

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6.

6. TO PRODUCE ONE BRICK

1. Start engine and put throttle to full revs. 2. Lid should be in the open position.

3. Hydraulic ram must be in the fully closed position.

4. Hydraulic ram lock plate must be in the out position as in the above picture.

7.

Piston Lock B

Ram Lock

Piston Lock A

Stroke limit piston plate in the DOWN position

Ram Lock in the OUT position

5. Fill chamber with soil by pulling hopper towards you fully and then pushing backwards and forwards to fill the chamber.

6. Close lid and put locks into place.

7. Extend ram to the fully open position using the spool valve, and put piston lock into position.

8.

Lid Lock A

Lid Lock B

Hopper

Piston Lock In

8. Fully retract the ram using the spool valve and move ram lock into lock position.

9. Open lid and fully extend ram using the spool valve. Remove brick by hand.

10. Retract ram fully using spool valve and remove ram lock.

9.

Ram Lock Out

Ram Lock In

Ram Lock Out

11. Remove piston lock

12. You are now ready to repeat from No. 5 above. PLEASE NOTE:

1. At no time should the chamber be filled by hand as this may end up with uneven compression which could cause the piston to distort.

2. After the brick has been removed you MUST retract ram fully BEFORE removing ram lock. Failure to follow the correct procedure may result in damage to the machine.

7. CURING OF BRICKS

Once you have made your bricks you need to cure them for at least 21 days to ensure a good strong brick. Level out an area close to where you are making your bricks, lay down a sheet of plastic to stack your bricks on. Do not stack more than five bricks high as this will damage the bottom bricks. The width you stack them will depend on the width of your plastic cover. You should also be able to reach the centre bricks from either side with a watering can so as to be able to water them. Once the bricks are made and stacked they should be covered immediately to stop them drying too quickly. They should then be watered once every day for between seven and 10 days. They should then be left for up to eleven days under plastic. This will ensure a good, cured brick.

8. FINISHING If you are not plastering the walls or pointing them, then use a soil/cement mixture to fill the joints or any chips that have occurred while building. This will leave your wall looking neat. A sealant may be a good idea to put on the inside and out, as this will also protect your walls better, and will make it easier to paint.

9. DISCLAIMER Ndume Ltd cannot guarantee the quality or strength of bricks made with this machine. Quality and strength of bricks is entirely dependent on soil type, ratio of mix, water content and curing technique. Ndume therefore accepts no responsibility for brick quality

10.

Piston Lock Out